CATALYST PRECURSOR COMPOSITION, AND METHOD OF MAKING THE SAME

Abstract: A catalyst precursor composition comprises the reaction product of a cation exchange resin containing trityl carbonium ions contacted with a metallocene. The process of producing the reaction product of a cation exchange resin containing trityl carbonium ions contacted with a metallocene comprises: (1) providing a cation exchange resin which has cations, (2) contacting the cation exchange resin with a solution comprising a trityl halide complex and solvent therefor to form an intermediate; and (3) contacting the intermediate with a metallocene, preferably a zirconocene salt. The resulting composition can be used to form ethylene resins in an alumoxane free system.

Description: Catalyst Precursor Composition, and Method of Making the Same The invention relates to a catalyst precursor composition and a method of making the same. The invention also relates to a catalyst which is useful in olefin polymerization. Low pressure or linear polyethylene is produced commercially using either Ziegler-Natta or supported chromium catalysts. These catalysts have high activities, and produce a variety of homopolymers and copolymers of ethylene and alpha olefins. When making copolymers, these catalysts typically produce resins of moderately broad to very broad molecular weight distribution. Ziegler-Natta and supported chromium catalysts produce copolymers of ethylene and alpha olefins of non-uniform branching distribution. The alpha olefins are preferentially incorporated into the lower molecular weight portions of the copolymer. This non-uniform incorporation affects polymer properties. At a given polymer density, higher comonomer percent incorporation is required and a higher polymer melting point is seen. For example, ethylene/1-hexene copolymers of 1.0 I 2 and 0.918 gm/cm 3 density produced by a typical Ziegler-Natta catalyst will contain 3.0 to 3.5 mole percent 1-hexene and have melting points of 126 to 127°C. Recently, a new type of olefin polymerization catalyst has been described. These catalysts are metallocene derivatives of transition metals, typically group IV transition metals such as zirconium, of the empirical formula Cp m MA n B p . These compounds are activated with methylaluminoxane (MAO) and produce olefin polymers and copolymers, such as ethylene and propylene homopolymers, and ethylene/butene and ethylene/hexene copolymers. These are described US-A-4542199 and US-A-4404344. Compared to earlier Ziegler-Natta catalysts, zirconocene/MAO catalysts produce polyethylene resins of relatively narrow molecular weight distribution and a highly homogeneous branching distribution. Ethylene/1-hexene copolymers of 1.0 I 2 and 0.918 gm/cm 3 density produced by these catalysts usually contain 2.5 mole percent 1-hexene and have melting points of 114 to 115°C. These resins can be used to make films of significantly higher impact strength and better clarity than those of resins prepared with standard Ziegler- Natta catalysts. A new series of reactions have been described in which dialkylzirconocenes (Cp 2 ZrRR where R and R' are straight chain hydrocarbon groups) are activated without aluminoxane to produce a catalytically active transition metal cation. Jordan et al, J. Amer Chem Soc. 1987, 109, 4111, has reacted Cp 2 ZrMe 2 with (Cp 2 Fe) + B(C 6 H 5 ) 4 - in CH 3 CN to produce Cp 2 ZrMe(CH 3 CN) + B(C 6 H 5 )„ " . This ionic complex has rather poor activity for olefin polymerization due to the coordinated solvent molecule. Common anions, such as B(C 6 H 5 ) 4 ~ , react with the zirconocene cation in the absence of a coordinating solvent. These reactions produce products that are not effective olefin polymerization catalysts. Stable, solvent-free, zirconocene cations have been produced by Chien et al, J. Amer. Chem. Soc. 1991, 113, 8570. Reacting Cp 2 ZrMe 2 with Ph 3 C + B(C 6 F 5 ) 4 " in a non-coordinating solvent produces Cp 2 ZrMe + B(C 6 F 5 ) 4 ~ . Likewise, Marks et al, J. Amer. Chem. Soc. 1991, 113, 3623, react Cp * 2 ThMe 2 with B(C 6 F 5 ) 3 in a non- coordinating solvent to produce Cp * 2 ThMe + MeB(C 6 F 5 ) 3 ". These ionic complexes are highly active olefin polymerization catalysts. Surprisingly, it has been found that a modified ion exchange resin can be used to generate the active metallocene cation. The resin serves both as a non reactive anion and as a catalyst support. According to one aspect of the present invention there is provided a catalyst precursor composition which comprises a cation exchange resin in which at least some of the exchangeable cationic sites comprise catalytic cationic metallocene species. Preferably, the metallocene species is provided by Cp m MA n B p , in which Cp is an unsubstituted or mono- or poly-substituted cyclopentadienyl group, M is a metallocene-for ing metal atom, and A and B, which may be the same or different, represent a halogen atom, a hydrogen atom, a hydroxyl group, an alkoxide group or an alkyl group, and wherein m is 1 or 2 and m+n+p is equal to the valency of M. Preferably the etallocene-forming metal atom is zirconium or hafnium, most preferably zirconium. In a preferred embodiment the Cp m MA n B p is bis-(indenyl)zirconium dihalide. Desirably, the resin contains anionic sites which comprise sulfonate groups. The Cp m MA n B p preferably comprises 0.01 to 2.0 mmol/g, more preferably 0.01 to 1.0 mmol/g, of the composition. It is preferred that the cationic exchange sites are exchangeable with Ph 3 C + . According to another aspect of the invention there is provided a process for preparing a catalyst precursor composition as described above, comprising contacting a cation exchange resin with a strongly Lewis acidic cationic species to form an intermediate; and contacting the intermediate with a metallocene to form a catalytic cationic metallocene species. The concentration of the Lewis acid cationic species should preferably be high enough to replace all the acidic or cationic sites on the resin. Preferably, said strongly Lewis acid cationic species is Ph 3 C + . Desirably said Ph 3 C + is provided in the form of trityl halide. The metallocene is preferably Cp m MA n B p , in which Cp is an unsubstituted or mono- or poly-substituted cyclopentadienyl group, M is a metallocene-forming metal atom, and A and B, which may be the same or different, represent a halogen atom, a hydrogen atom, a hydroxyl group, an alkoxide group or an alkyl group, and wherein m is 1 or 2 and m+n+p is equal to the valency of M. According to another aspect of the invention there is provided a catalyst comprising an alkylaluminum compound in combination with a catalyst precursor composition as described above. Preferably the alkyl group of the alkylaluminum compound contains 1 to 10 carbon atoms. Desirably the alkylaluminum compound is selected from the group consisting of alkylaluminum mono halides, alkylaluminum dihalides, and trialkylaluminum. The trialkylaluminum is preferably selected from the group consisting of trimethylaluminum, triethylaluminum and triisobutylaluminum; most preferably the trialkylaluminum is triisobutylaluminu . According to another aspect of the invention there is provided a process for the preparation of a homopolymer of ethylene, or a copolymer thereof with at least one alpha-olefin, said process comprising contacting a corresponding momomer with a catalyst as described above. According to another aspect of the invention there is provided the use of a cation exchange resin modified by exchange with a strongly Lewis acidic cationic species to produce a supported catalytic cationic metallocene species from the corresponding metallocene. Preferably, the strongly acidic cationic species is Ph 3 C + . Desirably, said corresponding metallocene is Cp m MA n B p , in which Cp is an unsubstituted or mono- or poly-substituted cyclopentadienyl group, M is a metallocene-forming metal atom, and A and B, which may be the same or different, represent a halogen atom, a hydrogen atom, a hydroxyl group, an alkoxide group or an alkyl group, and wherein m is 1 or 2 and m+n+p is equal to the valency of M. The catalyst of the invention acts as a high activity catalyst for the homopolymerization of ethylene, or the copolymerization of ethylene and an alpha olefin, to produce high molecular weight products preferably containing at least 60 percent of ethylene units, with an MFR value from 15 to 25. The catalyst according to the invention is free of aluminoxane and uses a cocatalyst comprising an alkylaluminum compound, in which each alkyl preferably contains 1 to 10, more preferably 1 to 8, carbon atoms and a catalyst precursor comprising a metallocene supported on an ion exchange resin. Ion exchange materials are sold as granules or spheres. The majority is prepared and sold in spherical (bead) form, from about 10 microns to 1.2 mm (up to 16 mesh) in diameter. Particle size and porosity are controlled by polymerization conditions; the preferred substrates are organic, resin materials. Conventional ion-exchange materials contain ion- active sites throughout their structure with a uniform distribution of activity, as a first approximation (cf KIRK OTHMER, ENCYCLOPEDIA OF CHEMICAL TECHNOLOGY, Vol. 13 p 168 (Third Edition) ) . The cationic portion of the cation exchange resin is generally a cation of an alkali or an alkaline earth metal. The anionic portion of the cation exchange resin preferably contains sulfonate groups. Most preferably, the cation exchange resin is a sulfonated copolymer of styrene and divinylbenzene. The ion exchange capacity of the cation exchange material ranges from 3 to 11 meq/gm. The cation exchange resin is in the form of porous particles, and is provided in the form of distinct particulate material. The distinct particulate material, in addition to being an essential component of catalyst synthesis as elucidated below, may also be a carrier or support with the attendant benefits that use of a support provides. In this respect, the use of the porous, crosslinked polymer particles as a catalyst support is distinct from the use of the polymeric materials as supports in prior art for olefin polymerization catalyst compositions. The polymer particles of the cation exchange resin have a spherical shape with particle diameter of about 1 to about 300 microns, preferably about 10 to about 150 microns and most preferably about 10 to about 110 microns. The particles are preferably chemically inert with respect to water, oxygen, organic solvents, organometallic compounds and halides of transition metals and are free flowing powders. They are preferably crosslinked by any conventional means, such as by cross linking agents, e.g., divinylbenzene., para-vinylstyrene, para-methylstyrene and trimethylacrylate under conventional crosslinking conditions, or by electromagnetic radiation in a conventional manner, e.g. , see KIRK-OTHMER ENCYCLOPEDIA OF CHEMICAL TECHNOLOGY, Third Edition, Volumen 19, pages 607-624, John Wiley & Sons, New York (1982) . The polymer particles may be manufactured from any suitable polymers, including thermoplastic, thermoset semicrystalline, amorphous, linear, branched or cross-linked polymers. Examples of suitable polymer used to manufacture the porous particles are polyethylene, polystyrene, poly(vinyl alcohol), poly(methyl methacrylate) , or poly(methyl acrylate) . The preferred carrier is a crosslinked polystyrene polymer. More preferably, the carrier is polystyrene crosslinked with divinylbenzene. The most preferred polymer particles are cross¬ linked polystyrene copolymers from Rohm & Haas Corp. under the tradename of Amberlite or Amberlyt. • In a preferred embodiment the cation exchange resin is contacted with a trityl halide, e.g. chloride. This contact results in displacement of the alkali or alkaline earth metal cation of the cation exchange resin. The amount of trityl chloride is based on the ion exchange capacity and ranges from 3 to 11 meq/gm, preferably 3 to 5 meq/gm. The contact results in ion exchange reaction between the cation exchange resin and the tritylchloride. The reaction is undertaken at a temperature ranging from 0 to 100°C, preferably 20 to 30°C, under air-free, water-free conditions. The tritylchloride treated cation exchange resin is then contacted with the metallocene to form a catalyst precursor. The amount of the metallocene can range from 0.01 to 2.0 mmol/g, more preferably from 0.01 to 1.0 mmol/g, and most preferably from 0.05 to 0.30 mmol/g. As described above, the metallocene salt or compound has the formula Cp m MA n B p . The substituents on the cyclopentadienyl group are preferably straight-chain C α -C 6 alkyl groups. The cyclopentadienyl group can be also a part of a bicyclic or a tricyclic moiety such as indenyl, tetrahydroindenyl, fluorenyl or a partially hydrogenated fluorenyl group, as well as a part of a substituted bicyclic or tricyclic moiety. In the case when m in the above formula of the metallocene compound is equal to 2, the cyclopentadienyl groups can be also bridged by polymethylene or dialkylsilane groups, such as -CH 2 -, -CH 2 -CH 2 -, -CR'R"- and -CR'R"-CR'R"- where R' and R" are short alkyl groups or hydrogen, -Si(CH 3 ) 2 -, Si(CH 3 ) 2 -CH 2 -CH 2 -Si(CH 3 ) 2 - and similar bridge groups. If the A and B substituents in the above formula of the metallocene compound are halogen atoms, they belong to the group of fluorine, chlorine, bromine or iodine. If the substituents A and B in the above formula of the metallocene compound are alkyl groups, they are preferably straight-chain or branched C-^-C-. alkyl groups, such as methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, n-pentyl, n-hexyl or n-octyl. Suitable metallocene compounds include bis(cyclopentadienyl)metal dihalides, bis(cyclopentadienyl)metal hydridohalides, bis(cyclopentadienyl)metal monoalkyl monohalides, bis(cyclopentadienyl)metal dialkyls and bis(indenyl)metal dihalides wherein the metal is zirconium or hafnium, halide groups are preferably chlorine and the alkyl groups are Cj-Cg alkyls. Illustrative, but non-limiting examples of metallocenes include bis(cyclopentadienyl) zirconium dichloride, bis (cyclopentadienyl) hafnium dichloride, bis (cyclopentadienyl ) zirconium dimethyl , bis ( cyclopentadienyl ) haf nium d imethyl , bis (cyclopentadienyl) zirconium hydridochloride, bis (cyclopentadienyl) hafnium hydridochloride, bis (pentamethylcyclopentadienyl) zirconium dichloride, bis(pentamethylcyclopentadienyl)hafnium dichloride, bis(n- butylcyclopentadienyl) zirconium dichloride, cyclopentadienyl- zirconium trichloride, bis(indenyl)zirconium dichloride, bis(4,5,6,7-tetrahydro-l-indenyl) zirconium dichloride, and ethylene-[bis(4, 5, 6, 7-tetrahydro-l-indenyl) ] zirconium dichloride. Most preferably, the metallocene compound is bis- (indenyl) zirconium dichloride. The metallocene compounds utilized within the embodiment of this art can be used as crystalline solids, as solutions in aromatic hydrocarbons. After the reaction is complete, a free-flowing powder is recovered by low temperature evaluation or nitrogen purge. After solvent removal, the product of the metallocene contact stage is a free flowing powder and may be used a catalyst precursor which is activated with an alkylaluminum cocatalyst or activator to form a catalyst composition free of aluminoxane. The precursor in combination with a cocatalyst acts as an olefin polymerization catalyst. Alkylaluminum and alkylaluminum halides, including alkylaluminum mono halides and alkylaluminum dihalides, in which the alkyl contains 1 to 10 carbon atoms are useful cocatalysts for olefin polymerization. Preferably, the cocatalyst is a trialkylaluminum, such as trimethylaluminu , triethylaluminum and triisobutylaluminum. Triisobutylaluminum is most preferred. The amount of cocatalyst in the composition, based on metallocene ranges from 1 to 1000, preferably 1 to 100. Cocatalyst contact with the precursor can be preferably effected in the polymerization reactor or prior to catalyst introduction into the reactor. All of the foregoing steps are undertaken under anhydrous conditions, in the absence of oxygen. The efficacy of the resulting composition in olefin polymerization catalysis is surprising. If a product is formed from the reaction of bis(indenyl) zirconium dichloride and trisisobutylaluminum, in the absence of the cation exchange resin, it does not act as a catalyst in ethylene polymerization. Moreover, if a product is formed from the reaction of bis(indenyl)zirconium dichloride, trisisobutylaluminum, and tritylchloride, in the absence of the cation exchange resin, it does not act as a catalyst in ethylene polymerization. Catalysts of the invention have an activity of at least about 1000-2000 g polymer/g catalyst or about 100-200 kg polymer/g transition metal. Although the catalysts can be used in the synthesis of any olefin polymers, such as aromatic or linear olefins, e.g., styrene or ethylene, they are preferably used as ethylene/alpha- olefin copolymerization catalysts. Accordingly, for the purposes of illustration, the invention will be described below in conjunction with alpha olefin catalyst synthesis. The catalyst of the invention exhibits high activity for polymerization of ethylene and higher alpha-olefins and allows the synthesis of ethylene polymers and copolymers with a relatively narrow molecular weight distribution and homogeneous branching distribution. The catalyst of the invention exhibits high activity for copolymerization of ethylene and higher alpha- olefins and allows the synthesis of linear low density polyethylene with a relatively narrow molecular weight distribution and homogeneous branching distribution. The molecular weight distribution is determined as MFR [I 2ι /I 2 ] which is preferably less than 25, more preferably from 18 to 24, and most preferably from 19 to 22, in polymerization products of the invention. Branching distribution in ethylene copolymers is evaluated on the basis of the resin's melting point. Relatively homogeneous branching distribution is one which the melting point ranges from 100 to 120°C, depending on comonomer composition. Ethylene homopolymers, as well as copolymers of ethylene with one or more C 3 -C 10 alpha-olefins, can be produced in accordance with the invention. Thus, copolymers having two monomeric units are possible as well as terpolymers having three monomeric units. Particular examples of such polymers include ethylene/1-butene copolymers, ethylene/1-hexene copolymers, ethylene/4-methyl-1-pentene copolymers, ethylene/propylene/1- hexene terpolymer, EPDM, and DCPD. Ethylene/l-butene and ethylene/1-hexene copolymers are the most preferred copolymers polymerized in the process of and with the catalyst of this invention. The ethylene copolymers produced in accordance with the present invention preferably contain at least about.60 percent by weight of ethylene units. Any heretofore known alpha-olefin polymerization processes can be used to polymerize alpha-olefins in the presence of the catalyst compositions of the present invention. Such processes include polymerizations carried out in suspensions, in solution or in the gas phase. Examples All procedures were performed under a dry nitrogen atmosphere. All liquids/solvents were anhydrous. Example 1. Catalyst Preparation A 250 cm 3 round bottom flask containing a magnetic stir bar and 100 cm 3 dichloromethane was charged with 5.0 g black Amberlite 124 beads. 7.0 g Ph 3 CCl was added, the slurry was stirred at room temperature and the solvent was decanted from the black beads. The beads were slurried in toluene and 400 mg (1.0 mmol) Ind 2 ZrCl 2 was added followed by 30 minutes of stirring at room temperature. The toluene was removed in vacuo at 50°C to leave a heterogeneous mixture of black and yellow catalyst. Example 2. Polymerization A 1 gallon (3.79 litre) stainless steel autoclave at room temperature was charged with 1500 cm 3 heptane and 350 cm 3 1- hexene. 2.9 cm 3 of 14 weight percent tri-iso-butylaluminum in hexane were added as a catalyst activator. The reactor was closed, and the temperature was brought to 70°C. 214.0 mg of catalyst was introduced with ethylene pressure. Ethylene was replenished on demand to keep reactor pressure constant at 145 psi (1000 KPa) . After 30 minutes, the reactor was vented and cooled to room temperature. 112 gm of copolymer were collected. I 2 = 0.02, MFR = 25.0, density = 0.905, T m = 115.2°C, mole % C 6 = 2.5. Thus it is apparent that there has been provided, in accordance with the invention, a composition that fully satisfies the objects, aims, and advantages set forth above. While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations may be made within the scope of the appended claims.

Claims: Claims 1. A catalyst precursor composition which comprises a cation exchange resin in which at least some of the exchangeable cationic sites comprise catalytic cationic metallocene species. 2. A composition according to Claim 1, wherein the metallocene species is provided by Cp m MA n B p , in which Cp is an unsubstituted or mono- or poly-substituted cyclopentadienyl group, M is a metallocene-forming metal atom, and A and B, which may be the same or different, represent a halogen atom, a hydrogen atom, a hydroxyl group, an alkoxide group or an alkyl group, and wherein m is 1 or 2 and m+n+p is equal to the valency of M. 3. A composition according to Claim 2, wherein the metallocene-forming metal atom is zirconium or hafnium. 4. A composition according to Claim 1, wherein the resin contains anionic sites which comprise εulfonate groups. 5. A composition according to Claim 2, wherein the Cp m MA n B p is bis-(indenyl) zirconium dihalide. 6. A composition according to Claim 2, wherein the Cp m MA n B p comprises 0.01 to 2.0 mmol/g of the composition. 7. A composition according to Claim 6, wherein the Cp m MA n B p comprises 0.01 to 1.0 mmol/g of the composition. 8. A composition according to Claim 1, wherein the cationic exchange sites are exchangeable with Ph 3 C + . 9. A process for preparing a composition according to claim 1, comprising contacting a cation exchange resin with a strongly Lewis acidic cationic species to form an intermediate; and contacting the intermediate with a metallocene to form a catalytic cationic metallocene species. 10. A process according to Claim 9, wherein said strongly Lewis acid cationic species is Ph 3 C + . 11. A process according to Claim 10, wherein said Ph 3 C + is provided in the form of trityl halide. 12. A process according to Claim 9, wherein said metallocene is Cp m MA n B p , in which Cp is an unsubstituted or mono- or poly- substituted cyclopentadienyl group, M is a metallocene-forming metal atom, and A and B, which may be the same or different, represent a halogen atom, a hydrogen atom, a hydroxyl group, an alkoxide group or an alkyl group, and wherein m is 1 or 2 and m+n+p is equal to the valency of M. 13. A catalyst comprising an alkylaluminum compound in combination with a catalyst precursor composition according to Claim 1. 14. A catalyst according to Claim 13, wherein the alkyl group of the alkylaluminum compound contains 1 to 10 carbon atoms. 15. A catalyst according to Claim 13, wherein the alkylaluminum compound is selected from the group consisting of alkylaluminum mono halides, alkylaluminum dihalides, and trialkylaluminum. 16. A catalyst according to Claim 15, wherein the trialkylaluminum is selected from the group consisting of trimethylaluminum, triethylaluminum and triisobutylaluminum. 17. A catalyst according to Claim 15, wherein the trialkylaluminum is triisobutylaluminum. 18. A process for the preparation of an olefin polymer, comprising contacting a corresponding momomer with a catalyst according to Claim 13. 19. A process according to Claim 18, wherein the olefin polymer is a homopolymer of ethylene, or a copolymer thereof with at least one alpha-olefin. 20. The use of a cation exchange resin modified by exchange with a strongly Lewis acidic cationic species to produce a supported catalytic cationic metallocene species from the corresponding metallocene. 21. The use of a cationic exchange resin according to claim 20, wherein the strongly acidic cationic species is Ph 3 C + . 22. The use of a cationic exchange resin according to claim 20, wherein said corresponding metallocene is Cp m MA n B p , in which Cp is an unsubstituted or mono- or poly-substituted cyclopentadienyl group, M is a metallocene-forming metal atom, and A and B, which may be the same or different, represent a halogen atom, a hydrogen atom, a hydroxyl group, an alkoxide group or an alkyl group, and wherein m is 1 or 2 and m+n+p is equal to the valency of M.

Inventors: FURTEK ALLAN BRENT, KRAUSE MICHAEL JOSEPH, FURTEK, ALLAN, BRENT, KRAUSE, MICHAEL, JOSEPH
Applicants: MOBIL OIL CORP, MOBIL OIL CORPORATION
Application year: 1994
Main classification: B01J31
IPC codes: B01J31, C08F4, C08F10